PCB Grounding Assembly for Brushless Fluid Pump Reliability
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Solution Overview
Problem
Existing automotive brushless electric fluid pumps face challenges in simplifying construction and reducing production costs due to complex assembly processes and multiple components.
Innovation Solution
A brushless electric fluid pump design featuring a longitudinal ground contact element with a flange portion soldered to the printed circuit board, which is mechanically and electrically connected to a massive electrical ground body without screws, allowing direct axial insertion and eliminating the need for additional fixation methods, thereby simplifying manufacturing and reducing parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional screw fixation is used to connect the printed circuit board to the ground body, then reliable electrical connection is achieved, but the number of parts increases and manufacturing complexity increases
Solution Approach 1:
The grounding element combines electrical connection and mechanical fixation functions into a single integrated component. The element has a first end that electrically connects to the printed circuit board and a second end that mechanically engages with the ground body through a press-fit connection, eliminating the need for separate screws or clips.
Solution Approach 2:
The grounding element serves multiple functions simultaneously: it provides electrical grounding connection, mechanical support for the printed circuit board, and structural integration with the ground body. This multi-functional design reduces the total number of components needed in the pump assembly.
2Reliability
If multiple separate components are used for grounding and fixation, then reliable connection is achieved, but production cost increases
Solution Approach 1:
The grounding element merges multiple separate components (grounding wire, fixation clip, mounting bracket) into a single integrated piece. This reduces assembly steps, lowers labor costs, and simplifies inventory management while maintaining reliable electrical and mechanical connections.
Solution Approach 2:
The grounding element is pre-formed with specific geometric features (cylindrical engagement portion, flange, bending direction) that enable direct press-fit installation. This preliminary preparation allows for quick assembly without requiring complex fixation procedures during manufacturing.
3Ease of manufacture
If a simple grounding element is used, then manufacturing is simplified, but reliable electrical connection may be compromised
Solution Approach 1:
The grounding element has varying cross-sectional properties along its length: a cylindrical engagement portion for mechanical insertion, a flange for positioning, and a connection end for electrical attachment. Each section is optimized for its specific function while maintaining overall manufacturing simplicity.
Solution Approach 2:
The grounding element acts as an intermediary component that bridges the printed circuit board and the ground body. Its intermediate geometric features (flange, cylindrical portion) facilitate reliable connection between these two components while keeping the overall design simple and manufacturable.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design simplifies the manufacturing process, reduces the number of components, and enhances the reliability of electrical connections, resulting in a more economical and efficient production of the fluid pump.
Implementation Method 1
a flange portion (62), which is soldered to the electrical ground contact (58') of the printed circuit board (42), so as to be electrically and mechanically connected to the electrical ground contact (58')
Data Source
Figure 1
Figure 2~3
AI summary
An automotive brushless electric fluid pump (10) wherein the fluid pump (10) comprises a pump unit (22) for pumping the fluid, a printed circuit board (42) for electronically commutating a driving motor (34) driving the pump unit (22), and a massive electrical ground body (50). The fluid pump (10) further comprises an electric circuit layer (58) comprising an electric ground contact (58'), which electric circuit layer (58) is provided on a side of the printed circuit board (42) facing the massive eiectrical ground body (50), and a longitudinal ground contact element (54), providing a flange portion (62), which is soldered to the electrical ground contact (58') of the printed circuit board (42), so as to be electrically and mechanically connected to the electrical ground contact (58') of the printed circuit board (42). The fluid pump (10) further comprises a bore (82) provided in the massive electrical ground body (50) for receiving a free end (76) of the ground contact element (54), wherein the ground contact element (54) is provided with a fixing portion (78), which is fixed in the bore (82), so as to mechanically and electrically connecting the ground contact element (54) with the massive electrical ground body (50).